Electrically operated actuator and method

Information

  • Patent Grant
  • 6282931
  • Patent Number
    6,282,931
  • Date Filed
    Thursday, May 4, 2000
    24 years ago
  • Date Issued
    Tuesday, September 4, 2001
    23 years ago
Abstract
A method is provided for retrofitting an existing dead-bolt assembly with an electrically operated actuator (12, 112, 212, 312, 800). The electrically operated actuator automatically operates the dead-bolt assembly while preserving manual operation of the lock. The actuator assembly has rotating means for rotation of the drive bar (18), which in turn extends or retracts the bolt (14) of the lock. The rotating means may be a lever (28, 128, 238, 328, 438, 818) attached to the drive bar (18) that is pivotable about the axis of rotation of the drive bar (18). The actuator assembly has driving means that forces the rotating means to rotate. The driving means is responsive to an electrical signal, which, for example, may be initiated from a remote-controlled transmitter (502, 602). The driving means may include a motor (20, 120, 220) for rotating a rod (22, 122, 222, 322) that in turn operates an assembly that rotates or drives the rotating means. In response to an electrical signal, the driving means actuates the rotating means to affect either a locking or unlocking operation, which operations are always completed by placing the actuator assembly in a state whereby the bolt of the lock may subsequently be extended or retracted manually, or automatically by the driving means.
Description




FIELD OF THE INVENTION




The present invention generally relates to an actuator assembly, and more specifically, to an electrically operated actuator for use with dead-bolt assemblies and other door locks.




BACKGROUND OF THE INVENTION




A convenient and reliable locking assembly for doors is a critical and important part of any security system. In commercial settings, property must be secured to prevent theft and vandalism. In residential settings, a convenient and reliable locking assembly may even be more important where the safety of the inhabitants is also at stake.




Traditionally, mechanically operated locking assemblies are used in which the operator inserts a key into the locking device and then rotates the key to retract or extend a bolting mechanism. While this mechanical solution is reliable, there are many inconveniences associated with using a mechanical key system. For example, for a person in a dark area, it is difficult to find the key, orient the key, and insert it into the lock. Also, for a person occupied with carrying items, it is difficult to manage the items and also manipulate a key. These are only a few of the many limitations and inconveniences associated with a mechanically operated locking system.




Electrically operated locking assemblies have been proposed to address the limitations of purely mechanical locks. For example, U.S. Pat. Nos. 3,733,861, 4,148,092 and 5,487,289, issued to Lester, Martin and Otto, III, et al., respectively, disclose electrically activated locks. However, these locks provide an electrically operated passive means for restraining manual operation of the bolt mechanism. These systems do not have an active means for extending and retracting the bolt mechanism directly. Further, some of these systems do not allow concurrent manual and electric operation.




Recently the automobile industry has adopted remote controlled devices to actuate automobile door locks. The convenience of these remote control capabilities is tremendous in comparison with mechanically operated locks and has been well accepted by consumers. However, the use of remote controlled locking systems for doors outside of the automobile industry has been limited due to no reliable and economical actuating assembly which can be used with doors and dead-bolt assemblies such as those found in residences. In particular, there is no actuating assembly which can be adapted to utilize conventional dead-bolt assemblies and also retain the ability to use the conventional key method of operating a dead-bolt assembly. Further, there is no actuating assembly that can be retrofit to an existing dead-bolt assembly.




Therefore, a need exists for an electrically operated actuator assembly for automation of the locking and unlocking of dead-bolt assemblies, and in particular, a need exists for an electrically operated actuator assembly that can preserve the conventional key method of operation and also be retrofit to an existing dead-bolt assembly.




SUMMARY OF THE INVENTION




Accordingly, an object of the present invention is to provide a convenient and reliable electrically operated actuating assembly.




A further object of the present invention is to provide an electrically operated actuator assembly which is adapted to respond to a remote transmitter/receiver device.




Another object of the present invention is to provide an electrically operated actuator assembly which can readily be adapted to dead-bolt assemblies for doors so that both a conventional key and a remote transmitter can be utilized to operate the dead-bolt assembly.




Another object of the present invention is to provide an electrically operated actuator assembly which can be easily added to, or retrofit for, a conventional dead-bolt assembly already installed on a door.




In accordance with the present invention, all of these objects, as well as others not herein specifically identified, are achieved generally by an electrically operated, remote-controlled actuator assembly which can be used with a locking system while preserving the option of using a key in a standard mode. More specifically, as discussed below, the present invention includes a driving means and a rotating means which operate on a conventional lock or dead-bolt assembly.




A conventional dead-bolt assembly includes a bolt, a drive bar, a cylinder which receives a conventional key on the exterior side of the door, and either a knob or another cylinder on the interior side of the door. The bolt is coupled to the drive bar such that rotation of the drive bar extends or retracts the bolt, depending on the direction of rotation. The exterior cylinder and the interior cylinder, if there is one, are coupled to the drive bar such that a key may be inserted into either cylinder and turned to rotate the drive bar, extending or retracting the bolt. Similarly, if there is a knob, rather than a cylinder, attached to the drive bar, the bolt can be extended or retracted by rotation of the knob.




In accordance with the present invention, a rotating means is coupled to the drive bar such that the rotating means is capable of rotating the drive bar and thus the bolt. The driving means, in response to an electrical signal, actuates the rotating means to effect the extension or retraction of the bolt, causing a locking or unlocking operation. After actuation by the driving means, the rotating means is placed in a state whereby the bolt may be extended or retracted manually, that is, by use of a key or knob, or automatically by the driving means.




In one embodiment, the rotating means includes a resilient lever that is attached to the drive bar to rotate the drive bar, causing the bolt to extend and retract. The resilient lever has an axis of rotation that is coaxial with the axis of rotation of the drive bar. The driving means includes a motor capable of bidirectional rotation of a threaded rod extending therefrom. A threaded member is screwed onto the threaded rod, but means are provided to prevent rotation of the threaded member about the threaded rod, thereby allowing the threaded member to extend along the length of the threaded rod, depending on the direction of rotation of the motor. The threaded member has a protrusion positioned to engage the lever and pivot the lever from a first position wherein the bolt is extended, to a second position wherein the bolt is retracted. The lever is resilient so that the protrusion on the threaded member may force the lever out of its path when the lever has reached the end of its range of rotation, for example, when the lever has attained the first position or the second position. This allows the protrusion to be placed in a position such that the lever is free for rotating manually, as is required for key or knob operation, and also places the protrusion in position for reciprocal movement of the lever.




In another embodiment, the rotating means includes a rigid, non-resilient lever that is attached to the drive bar to rotate the drive bar, causing the bolt to extend and retract. The rigid lever has an axis of rotation that is coaxial with the axis of rotation of the drive bar and is pivotable from a first position wherein the bolt is extended, to a second position wherein the bolt is retracted. The driving means includes a bidirectional motor capable of rotating a threaded rod extending therefrom. An actuating arm with a first protrusion at one end of the arm and a second protrusion at the opposite end of the arm is threaded onto the threaded rod such that rotation of the motor causes the arm to extend along the length of the threaded rod. The actuating arm is placed with respect to the lever such that the levers range of motion, that is, from the first position to the second position, is always between the first and second protrusions of the actuating arms. Thus, one protrusion can be extended by the motor to pivot the lever from the first position to the second position, while the second protrusion can be extended by the motor to pivot the lever from the second position to the first position. Whenever the motor is cycled to force the lever to a particular position, after the desired position is obtained, the motor automatically cycles in the opposite direction to place the protrusions in position for manual operation of the lock and for subsequent electrical operation. For fail-safe operation, the first and second protrusions on the actuating arm may be cantilevered such that the lever may be manually forced over either protrusion if, for example, the motor fails leaving either protrusion in a position adverse to manual operation.




Several other alternatives for driving means, including solenoids are disclosed. Additionally, alternative rotating means including circular gears and various lever arrangements are disclosed. Preferably, the rotating means includes an adaptor that is easily positioned over a drive bar of an existing lock, the adaptor including either the resilient or non-resilient lever and an extended drive bar for receiving a knob or interior cylinder.




Electrical activation is accomplished in the invention by use of a remote control unit. The remote control unit includes at least a transmitter, a receiver and a control circuit. Preferably, the transmitter is also a receiver or a transmitter/receiver and the receiver is also a transmitter or a receiver/transmitter. The transmitter/receiver sends a signal to lock or unlock. The signal is received by the receiver/transmitter and sent to the control circuit. The control circuit activates the driving means in accordance with the signal received by the receiver/transmitter and monitors the status of the lock. The status monitored by the control circuit, as determined by appropriate sensors, includes successful or unsuccessful completion of rotation of the rotating means to the locked or unlocked position, or sensing the position of the driving means, or sensing the position of the rotating means and the driving means. The status determined by the control circuit is sent by the receiver/transmitter to the transmitter/receiver, which may give a visual and/or audible indication to the user.




The circuits used for electrical activation are preferably battery powered and thus require low power operation and judicious power management. This is accomplished in part by switching power to components only as needed. Also, components have multiple functions that may be time multiplexed for efficient use and low power operation. Further, the voltage of the batteries may be sensed and the current for the driving means may be sensed to ensure proper operation and detect problems and failures.




The invention includes a method for retrofitting an existing lock or dead-bolt assembly with an electrically operated actuator. The existing lock has an interior cylinder or knob, an exterior cylinder, a drive bar and existing mounting hardware, such as bolts. In accordance with one method, first the interior cylinder or knob is removed. Then, a support plate having an opening formed therein and a preassembled actuator in accordance with the present invention mounted thereon is mounted on the door such that the opening formed in the plate receives the existing mounting hardware from the exterior cylinder. A mounting plate is then aligned over the support plate such that bores in the mounting plate receive the existing mounting hardware from the exterior cylinder. A lever having an axis of rotation that is coaxial with an axis of rotation of the drive bar is coupled to the drive bar prior to securely reattaching the interior cylinder or knob and any desired protective cover.




In accordance with another method for retrofitting an existing lock or dead-bolt assembly with an electrically operated actuator, the interior cylinder or knob is removed. Then an adaptor is placed on to the existing drive bar. One end of the adaptor is adapted to receive the drive bar and the other end of the adaptor is adapted to be received by a lever assembly housed within a preassembled actuator that includes in addition to the lever assembly, a knob or cylinder, a cover, and a base plate with an actuator mounted thereon. The preassembled actuator is aligned over the adaptor with the lever assembly positioned to receive the adaptor. Mounting hardware is used to secure the preassembled actuator on to the existing lock. dr




BRIEF DESCRIPTION OF THE DRAWINGS




Further objects of the invention, taken together with additional features thereto and advantages occurring therefrom, will be apparent from the following description of the invention when read in conjunction with the accompanying drawings, wherein:





FIG. 1

is a perspective view of a dead-bolt assembly coupled with an electrically operated actuator embodiment in accordance with the present invention, wherein the dead-bolt assembly is in the locked position;





FIG. 1A

is a perspective view of the dead-bolt assembly and actuator shown in

FIG. 1

, wherein the dead-bolt assembly is in the unlocked position;




FIG


2


is a perspective view of a dead-bolt assembly coupled with another electrically operated actuator embodiment in accordance with the present invention, wherein the dead-bolt assembly is in the locked position;





FIG. 2A

is a perspective view of the dead-bolt assembly and actuator shown in

FIG. 2

, wherein the dead-bolt assembly is in the unlocked position;





FIG. 3

is a perspective view of a dead-bolt assembly coupled with a third embodiment of an actuator in accordance with the present invention, wherein the dead-bolt assembly is in the locked position;





FIG. 3A

is a perspective view of the dead-bolt assembly and actuator shown in

FIG. 3

, wherein the dead-bolt assembly is in the unlocked position;





FIG. 4

is a perspective view of a dead-bolt assembly coupled with a fourth embodiment of an actuator in accordance with the present invention wherein the dead-bolt assembly is in the locked position;





FIG. 4A

is a perspective view of the dead-bolt assembly and actuator shown in

FIG. 4

, wherein the dead-bolt assembly is in the unlocked position;





FIG. 4B

is a front perspective view of a one-piece adaptor including a lever and extended drive bar for use with the embodiment shown in

FIG. 4

;





FIG. 4C

is a back perspective view of an arrangement for the one-piece adaptor in

FIG. 4B

;





FIG. 4D

is a back perspective view of an alternate arrangement for the one-piece adaptor shown in

FIG. 4B

;





FIG. 4E

is a back perspective view of another arrangement for the one-piece adaptor shown in

FIG. 4B

;





FIG. 5

is a perspective view of an alternative arrangement of the actuator embodiment shown in

FIG. 4

, wherein the alternative arrangement includes solenoids;





FIG. 6

is a perspective view of an alternative arrangement of the actuator embodiment shown in

FIG. 3

;





FIG. 7

is a block diagram of a remote control system that controls an actuator in accordance with the present invention;





FIG. 8

is a block diagram of a remote control system that controls and reports status of an actuator in accordance with the present invention;





FIG. 9

is a front plan view of a plate having a mounting portion in a first position for retrofitting an existing dead-bolt assembly with an actuator in accordance with the present invention;





FIG. 10

is a front plan view of the plate of

FIG. 9

with the mounting portion in a second position;





FIG. 11

is a front plan view of the plate of

FIG. 9

with the mounting portion removed;





FIG. 12

is a cross-sectional view of the plate shown in

FIG. 9

taken along line


12





12


;





FIG. 13

is a perspective view of another electrically operated actuator embodiment in accordance with the present invention;





FIG. 14

is a schematic diagram of an embodiment implementing control circuitry for a remote control for use with an actuator in accordance with the present invention;





FIG. 15

is a schematic diagram of a transmitter for a remote control for use with an actuator in accordance with the present invention;





FIG. 16

is a schematic diagram of a receiver for a remote control for use with an actuator in accordance with the present invention;





FIG. 17

is a schematic diagram of a portion of the control circuitry of a door unit including an actuator in accordance with the present invention;





FIG. 18

is a schematic diagram of a portion of the control circuitry of a door unit including an actuator in accordance with the present invention;





FIG. 19

is a schematic diagram of a transmitter for a door unit including an actuator accordance with the present invention;





FIG. 20

is a schematic diagram of a receiver for a door unit including an actuator in accordance with the present invention;





FIG. 21

is a side view of the actuator shown in

FIG. 13

;





FIG. 22

is an exploded perspective view of the actuator shown in

FIG. 13

with a cover, knob and adaptor; and





FIG. 23

is an exploded perspective view of the actuator shown in

FIG. 13

with an adaptor.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS





FIG. 1

shows a dead-bolt assembly, generally designated as


10


, which can be driven by an electrically operated actuator, generally designated as


12


, in accordance with the present invention. The dead-bolt assembly


10


consists of a bolt


14


, an exterior drive cylinder


16


and a drive bar


18


. An interior drive cylinder (not shown), or knob (not shown), may be attached to the end of drive bar


18


opposite exterior drive cylinder


16


. Drive bar


18


is coupled to bolt


14


in a conventional manner such that rotation of drive bar


18


extends or retracts bolt


14


. Cylinder


16


is coupled to drive bar


18


in a conventional manner such that rotation of a proper key in cylinder


16


rotates drive bar


18


. Thus, drive cylinder


16


extends or retracts bolt


14


depending on the rotational direction of the key.




Drive cylinder


16


and bolt


14


are separated from electrically operated actuator


12


by a plate


34


having an opening (not shown) for the drive bar


18


to extend through. Plate


34


may be mounted to the door (not shown). Plate


34


is not necessary, but provides a convenient base to which electrically operated actuator


12


may be mounted. Any similar substitute structure would suffice.




The embodiment of the electrically operated actuator assembly


12


depicted in

FIG. 1

, consists of driving means, including a motor


20


and a threaded rod


22


; and rotating means, including a nut


24


, an adaptor


26


, a lever


28


and a guide


32


. It is preferable to secure motor


20


to plate


34


. Threaded rod


22


is connected at one end to electric motor


20


, which is capable of bidirectional rotation and also has overload protection. Nut


24


has a hole that is threaded for receiving threaded rod


22


, and a tongue


36


that extends radially outward from nut


24


. Adaptor


26


is secured on drive bar


18


and is utilized to secure resilient lever


28


to extend radially away from drive bar


18


. Resilient lever


28


is either spring-loaded, as is known in the art, or is sufficiently resilient so that it can be pushed to one side or the other and will always return to its original position. Guide


32


, preferably secured onto mounting plate


34


, defines a channel adapted to receive tongue


36


and to allow sliding movement of tongue


36


along the length of the channel. Guide


32


is aligned in parallel orientation with threaded rod


22


so that tongue


36


will remain in the channel throughout movement of the nut


24


along the length of threaded rod


22


.




When motor


20


is activated, threaded rod


22


is rotated. Depending on the direction of rotation and threading, nut


24


will be raised or lowered along the length of rod


22


from a first or locked position to a second or unlocked position. Tongue


36


is retained in guide


32


to prevent nut


24


from rotating.




From the locked position shown in

FIG. 1

, motor


20


can be activated to unlock dead-bolt assembly


12


by raising nut


24


. As nut


24


is raised, tongue


36


will exert an upward force on lever


28


, moving lever


28


towards the upper or unlocked position, causing drive bar


18


to rotate counterclockwise. The rotation of drive bar


18


will cause bolt


14


to retract, thus unlocking the door. Drive bar


18


does not rotate further counterclockwise once bolt


14


is fully retracted. (See nut


24


in phantom in FIG.


1


A). However, motor


20


continues to drive nut


24


upward, pushing it through the flexing resilient lever


28


, until tongue


36


is driven beyond lever


28


. Lever


28


then rebounds to its original position. As shown in

FIG. 1A

, tongue


36


is then ready to drive lever


28


in an opposite direction, i.e., back to the locked position. Additionally, tongue


36


is positioned not to interfere with lever


28


if a user rotates drive bar


18


by using a key or knob.




From the unlocked position shown in

FIG. 1A

, motor


20


can be activated to lock dead-bolt assembly


12


by lowering nut


24


until it pushes lever


28


downward, thus causing the drive bar


18


to rotate in a clockwise direction. The rotation of drive bar


18


extends bolt


14


. Once bolt


14


is fully extended, drive bar


18


does not rotate further in the clockwise direction. However, nut


24


continues in its downward path until tongue


36


pushes through resilient lever


28


. After tongue


36


is driven beyond lever


28


, as shown in

FIG. 1

, motor


20


stops operation. Resilient lever


28


then rebounds to its original position such that tongue


36


is in a position to catch lever


28


when tongue


36


is driven in the opposite direction. Notably, when motor


20


stops operation, tongue


36


is positioned not to interfere with manual operation of dead-bolt assembly


10


, that is, operation with a key or knob.




Turning now to

FIG. 2

, dead-bolt assembly


10


is shown driven by an electrically operated actuator


112


in accordance with another embodiment of the present invention. A motor


120


is horizontally oriented such that a threaded rod


122


attached to motor


120


and a guide


132


are parallel to bolt


14


. In this embodiment, guide


132


receives a portion of a generally cylindrical nut


124


, which is capable of sliding movement along the length of the channel defined by guide


132


. Nut


124


is provided with two prongs


136


(see

FIG. 2A

) which extend radially out from nut


124


and rest along guide


132


. Prongs


136


prevent rotation of nut


124


when threaded rod


122


is rotated by motor


120


. A U-shaped lever


128


having a pair of resilient arms


138


is secured directly onto drive bar


18


.




Motor


120


is activated to rotate threaded rod


122


, which in turn causes linear movement of nut


124


along guide


132


to affect a locking or unlocking operation. For example, dead-bolt assembly


110


is shown in a locked position in FIG.


2


. If an unlocking operation under control of electrically operated actuator


112


is desired, motor


120


is activated to cause nut


124


to move in the direction of arrow A. Prongs


136


of nut


124


contact resilient arms


138


of lever


128


. The progression of nut


124


along guide


132


causes prongs


136


to force resilient arms


138


to rotate lever


128


, causing a corresponding rotation of drive bar


18


, which results in the retraction of bolt


14


. Drive bar


18


reaches the end of its rotational travel when bolt


14


is completely retracted. This prevents further rotation of lever


128


. However, motor


120


continues to extend nut


124


along guide


132


, forcing prongs


136


to bend resilient arms


138


, eventually forcing prongs


136


and nut


124


to extend beyond resilient arms


138


, as shown in FIG.


2


A. When motor


120


stops, prongs


136


are positioned beyond resilient arms


138


to facilitate manual operation of the lock and also to facilitate a locking operation by reversing the direction of motor


120


.





FIG. 3

shows another embodiment of an electrically operated actuator assembly


212


coupled to dead-bolt assembly


10


. Electrically operated actuator assembly


212


has a motor


220


that rotates a rod


222


. Attached to rod


222


is a first threaded gear


224


. A lever


238


is attached to drive bar


18


such that rotation of lever


238


causes rotation of drive bar


18


. Between lever


238


and plate


34


is a circular gear


270


having teeth


271


along its perimeter. Gear


270


is mounted in a known manner for rotation about an axis coaxial to drive bar


18


. Circular gear


270


has three protrusions


236




a-c


which are spaced an equal distance apart from each other near the perimeter of circular gear


270


. Protrusions


236




a-c


are sized to contact lever


238


for rotating lever


238


. Circular gear


270


and threaded gear


224


are positioned in cooperation such that rotation of threaded gear


224


causes corresponding rotation in circular gear


270


. Lever


238


is resilient in a direction parallel to the axis of rotation of drive bar


18


.




To effect a locking or unlocking operation with electrically operated actuator assembly


212


, motor


220


drives threaded gear


224


, which in turn rotates circular gear


270


. Rotation of circular gear


270


causes one of protrusions


236




a-c


to frictionally engage lever


238


and rotate lever


238


. Rotation of lever


238


rotates drive bar


18


causing bolt


14


to extend or retract, depending upon the direction of rotation.




For example, dead-bolt assembly


10


is shown in a locked position in FIG.


3


. If an unlocking operation is desired using the electrically operated actuator assembly


212


, motor


220


is driven such that circular gear


270


rotates in a counterclockwise direction. Protrusion


236




a


contacts lever


238


, forcing lever


238


to rotate drive bar


18


until bolt


14


retracts. After bolt


14


retracts, rotation of lever


238


is prevented by drive bar


18


, which has fully rotated to its unlocked position. However, motor


220


continues to drive circular gear


270


such that protrusion


236




a


causes lever


238


to bend outwardly, allowing protrusion


236




a


to be rotated beyond lever


238


, as shown in FIG.


3


A. Once protrusion


236




a


has extended just beyond lever


238


, motor


220


is halted. As shown in

FIG. 3A

, the dead-bolt assembly is then in position to be manually operated or to be electrically operated by actuator


212


.




In embodiments of the invention shown in

FIGS. 1-3

, the levers,


28


,


128


and


238


are resilient to allow the electrically operated actuator assembly


212


to achieve a position whereby the actuator does not interfere with manual operation and such that the actuator is in position for the reciprocating operation. An alternative preferred embodiment is shown in

FIG. 4

, whereby no resilient member is required, thereby simplifying the design.





FIG. 4

shows dead-bolt assembly


10


with an electrically operated actuator assembly


312


in accordance with the present invention. Actuator assembly


312


is mounted to plate


34


and includes motor


320


, threaded rod


322


and a threaded actuating arm


324


. Actuating arm


324


has a guide portion


332


that abuts against plate


34


preventing rotation of actuating arm


324


. Actuating arm


324


has a first end portion


336




a


and a second end portion


336




b


. A lever


328


is secured to drive bar


18


to rotate drive bar


18


and extend or retract bolt


14


, depending upon the direction of rotation. End portions


336




a-b


of actuating arm


324


are sized and positioned to define the ends of the range of rotation of lever


328


.




A preferred alternative to having a separate lever


328


that is secured onto the existing drive bar


18


is to provide a drive bar adaptor


329


, as shown in

FIG. 4B

, which includes lever portion


328




a


and extended drive bar


18




a


. Extended drive bar


18




a


provides a physical extension of drive bar


18


, making adaptor


329


particularly useful for retrofitting the actuator assembly


312


to an existing lock, which may have a relatively short drive bar. Similar drive bar adapters may be substituted for adaptor


26


and lever


28


, lever


128


and lever


238


.





FIGS. 4C-4E

shows alternate arrangements for the back portion of drive bar adaptor


329


. The alternate arrangements are sized and configured to account for variations in drive bar arrangements from different lock manufacturers. An extended interior drive bar


331




a


is shown in

FIG. 4C

; a D-shaped hole


331




b


for receiving a D-shaped drive bar is shown in

FIG. 4D

; and a rectangular hole


331




c


for receiving a drive bar complimentary in shape is shown in FIG.


4


E.




To effect a locking or unlocking operation, motor


320


is activated to rotate threaded rod


322


, causing actuating arm


324


to move upward or downward along and parallel to threaded rod


322


. Movement of actuating arm


324


causes end portions


336




a


or


336




b


to frictionally engage and rotate lever


328


causing rotation of drive bar


18


and the extension or retraction of bolt


14


.




In

FIG. 4

, dead-bolt assembly


10


is shown in a locked position. To effect an unlocking operation, motor


320


is activated to drive actuating arm


324


in an upward direction. This causes end portion


336




b


to contact and rotate lever


328


. Continued movement of actuating arm


324


rotates lever


328


until bolt


14


is completely retracted. Once the bolt


14


is fully retracted (see actuator arm in phantom in FIG.


4


A), motor


320


automatically reverses its direction causing actuating arm


324


to move downward until it reaches the position shown in FIG.


4


A. As readily seen in

FIG. 4A

, dead-bolt assembly


10


is in position to be manually operated or for a subsequent operation by electrically operated actuator assembly


312


.




It will be appreciated by those skilled in the art that changes and modifications may be made to the embodiments described above without departing from the invention in its broader aspects. One such modification of the invention is shown in

FIG. 5

, wherein actuator assembly


312


shown in

FIG. 4

is modified replacing motor


320


with two (2) solenoids


321


,


319


. Solenoid


319


has a core


352


that may be extended or retracted. Solenoid


319


is mounted such that core


352


may contact lever


328


and force it from the locked to the unlocked position. Solenoid


321


has a core


350


that is positioned such that it may contact lever


328


and force it from the locked to the unlocked position.

FIG. 5

shows dead-bolt assembly


10


in the locked position. The dead-bolt assembly


10


is unlocked by actuating solenoid


319


such that core


352


pushes lever


328


such that drive bar


18


is rotated and bolt


14


is retracted. Then solenoid


319


is actuated such that core


352


is retracted. This places the assembly in position to be manually operated or electrically actuated. Similarly, a locking operation is affected by solenoid


321


being actuated to extend core


350


such that it rotates lever


328


causing the extension of bolt


14


. Solenoid


321


is then actuated to retract core


350


, placing the assembly in position for manual or subsequent automatic operation.





FIG. 6

shows a modification to the actuator embodiment shown in FIG.


3


. Protrusions


236




a


and


236




b


are replaced with protrusions


436




a


and


436




b


, which are sized to extend beyond lever


438


. A protrusion corresponding to


236




c


is not required. Additionally, gear


470


only needs approximately half as many teeth


471


as gear


270


. Rigid lever


438


replaces lever


238


in this modification and need not be resilient, but may be resilient to facilitate fail-safe operation, as discussed below in conjunction with FIG.


13


.

FIG. 6

shows dead-bolt assembly


10


in the locked position. Assembly


10


is unlocked by activating motor


220


to rotate circular gear


470


counterclockwise, thereby rotating lever


438


causing drive bar


18


to retract bolt


14


. Once bolt


14


has reached the completely retracted position, motor


220


automatically reverses turning circular gear


470


clockwise until gear


470


returns to its position shown in FIG.


6


. Similarly, assembly


10


is locked by rotating circular gear


470


clockwise until bolt


14


completely extends, and then rotating circular gear


470


counterclockwise until gear


470


returns to its position shown in FIG.


6


.





FIG. 13

is an additional preferred embodiment of an electrically operated actuator in accordance with the present invention. Electrically operated actuator


800


has a motor


802


that rotates an optional gear reduction assembly


804


that in turn rotates a threaded rod


806


. An actuating arm or carriage


808


is in threaded engagement with threaded rod


806


such that actuating arm


808


travels along the length of threaded rod


806


. Actuating arm


808


is prevented from rotating about threaded rod


806


due to a raised portion (not shown) on actuating arm


808


that rests within a groove


810


in base plate


812


. Two angled protrusions


814


,


816


are cantilevered on actuating arm


808


for rotating a lever


818


, which in turn actuates drive bar


820


, which rotates a conventional bolt mechanism (not shown).




The actuator


800


operates substantially as the actuator


312


shown in

FIGS. 4-4A

. The angled protrusions


814


,


816


are sized and positioned to define the ends of the range of rotation of lever


818


. To effect a locking or unlocking operation, motor


802


is activated to rotate threaded rod


806


, causing actuating arm


808


to move upward or downward along and parallel to threaded rod


806


. Movement of actuating arm


808


causes one of angled protrusions


814


or


816


to frictionally engage and rotate lever


818


causing rotation of drive bar


820


and the extension or retraction of the bolt. As with actuator assembly


312


, motor


802


rotates in one direction to lock or unlock, then automatically reverses at the end of the desired operation to place the actuating arm in a neutral position to facilitate manual operation or subsequent electrical operation. The neutral position allows lever


818


to rotate within its range of movement without interference from actuating arm


808


.




Angled protrusions


814


,


816


provide additional advantages for fail-safe operation of actuator


800


by allowing manual locking and unlocking operation even when the actuating arm is not in a neutral position. For example, if actuator


800


fails with actuating arm in the position shown in

FIG. 13

, lever


818


may be forced counterclockwise, pushing the cantilevered angled protrusion out of its path to effect a lock or unlock operation. Angled protrusions


814


,


816


are angled on one side at a different slope than the other side to present different levels of force to overcome the actuating arm in case of failure. Thus, after a lock or unlock operation that forces lever


818


from between angled protrusions


814


,


816


, less force is required to return lever


818


to a position between angled protrusions


814


,


816


. An alternative to a rigid lever, such as lever


818


, and cantilevered angled protrusions


814


,


816


, is to have a resilient lever such as lever


238


and rigid protrusions on actuating arm


808


.




The electronic controls for activating and deactivating the actuator assembly in accordance with the present invention may be accomplished in any known manner. Preferably, the actuator is controlled by a remote control transmitter and receiver which, for example, may operate using radio frequency (RF). Alternatively, the actuator may be controlled by a keypad collocated or remote from the lock.





FIG. 7

is a block diagram illustrating an embodiment for controlling actuator assembly


12


. A circuit


500


is composed of an RF transmitter


502


, RF receiver


504


, and a control circuit


505


, including a code detection circuit


508


and microcontroller


512


. RF transmitter


502


transmits, via radio frequency, preferably encrypted codes to lock and unlock the actuator assembly. Preferably, RF transmitter


502


is of the type commonly used with automobile locks. RF receiver


504


receives radio frequency signals transmitted by transmitter


502


and creates a demodulated signal


506


that is transmitted to code detection circuit


508


. Code detection circuit


508


determines whether a valid signal was received from the transmitter


502


. A valid/nonvalid indication


510


is transmitted by code detection circuit


508


to microcontroller


512


. If a valid signal was received, microcontroller


512


deciphers the command requested. Microcontroller


512


then sends the appropriate activation signals


516


to the actuator assembly to lock or unlock the actuator assembly. Microcontroller


512


also monitors the status of the actuator assembly via status signals


514


. As an alternative to a separate code detection circuit, the microcontroller may implement the code detection circuit.





FIG. 8

is a block diagram illustrating a preferred embodiment for controlling actuator assembly


12


and receiving status information from actuator assembly


12


. A circuit


600


is composed of two transceivers, an RF transmitter/receiver


602


and RF receiver/transmitter


604


, and a control circuit


605


, including a code detection/generation circuit


608


and microcontroller


612


. Additionally, for sensing the status of the actuator assembly, lock sensor


618


and unlock sensor


620


are provided.




For controlling actuator assembly


12


, circuit


600


operates in a manner similar to circuit


500


. RF transmitter/receiver


602


transmits, via radio frequency, preferably encrypted codes to lock and unlock the actuator assembly. RF receiver/transmitter


604


receives radio frequency signals transmitted by transmitter/receiver


602


and creates a demodulated signal


606


that is transmitted to code detection/generation circuit


608


. Code detection/generation circuit


608


determines whether a valid signal was received from transmitter/receiver


602


. A valid/nonvalid indication


610


is transmitted by code detection/generation circuit


608


to microcontroller


612


. If a valid signal was received, microcontroller


612


deciphers the command requested. Microcontroller


612


then sends the appropriate activation signals


616


to the actuator assembly to lock or unlock the actuator assembly.




Lock sensor


618


and unlock sensor


620


are provided to detect the status of the dead-bolt assembly and the actuator assembly. Lock sensor


618


provides an indication that the dead-bolt assembly has been successfully locked. Unlock sensor


620


provides an indication that the dead-bolt assembly has been successfully unlocked. The sensors may be reed switches with a magnet, Hall effect switches with a magnet, optical sensors, metal electrical contacts, or mechanical switches. The sensors may sense, for example, the position of the actuating arm or the lever or both. Additional sensors may be used to sense additional positions of the actuator assembly or lock.




The status of the actuator assembly and the lock as determined from any sensors, such as lock sensor


618


and unlock sensor


620


, may be transmitted to the microcontroller via status signals


614


. Microcontroller


612


may alert code detection/generation circuit


608


to generate an appropriate status signal via status line


611


. Code detection/generation circuit


608


may then create a modulated signal


607


which is transmitted via RF receiver/transmitter


604


to RF transmitter/receiver


602


. The status received by RF transmitter/receiver


602


may be used to generate a visual or audible indication of status to the user.




The electronics for controlling the actuator assembly in accordance with the present invention are preferably battery powered and most preferably, include a visual and/or audible indication of a low battery condition.





FIGS. 14-20

are schematic diagrams of a preferred embodiment for implementing the electronics for controlling the actuator assembly in accordance with the present invention.

FIGS. 14-16

are the schematic diagrams for the remote control or fob used to send signals to the actuator and receive status signals from the actuator.

FIG. 14

is the schematic for the control circuitry for the fob and

FIGS. 15 and 16

are the schematics for the transmitter and receiver, respectively, for the fob.

FIGS. 17-20

are the schematic diagrams for the door unit lock circuitry, which includes the electronics located with the actuator assembly for controlling the actuator and receiving and transmitting signals from and to the fob. The door unit control circuitry is shown in

FIGS. 17-18

and the transmitter and receiver portions of the door unit circuitry are shown in

FIGS. 19 and 20

, respectively.




Referring to

FIG. 14

, the remote control or fob has four switches FSW


1


, FSW


2


, FSW


3


, FSW


4


and is battery operated. The terminals for the battery are FTP


1


and FJ


1


, representing positive and negative, respectively. At the heart of the fob control circuitry is a microprocessor FU


2


. The preferred microprocessor is a Z86C04 available from Zilog. However, any suitable microprocessor may be used.




Microprocessor FU


2


has power and ground inputs, VCC and GND, clock/crystal inputs XTAL


1


-


2


and general purpose input/output ports P


0


, P


2


and P


3


. Port inputs P


0


_


0


-


2


are used to interface to a hopping encoder FU


1


, which is preferably a HCS300 from Microchip. Hopping encoder FU


1


is used to encrypt the data that will be transmitted by the fob. Port P


2


_


4


is used as an output to generate an unencrypted transmit signal. The transmit signal FTXD, which may be derived from port P


2


_


4


and/or hopping encoder FU


1


, is sent to the transmitter circuit (

FIG. 15

) for transmission.




Ports P


2


_


0


-


3


are inputs connected to switches FSW


1


, FSW


2


, FSW


3


and FSW


4


, respectively. The switches FSW


1


-


4


are normally open contacts that when closed place VCC on the corresponding port inputs. The switch inputs allow the user to give commands such as lock and unlock to microprocessor FU


2


. As an alternative to switches for the user to enter commands, a keypad or other input device may be used.




Ports P


2


_


6


and P


2


_


7


are used to provide a voltage to two contacts FJ


2


, FJ


3


of a buzzer for generating an audio alarm. Adjusting the frequency of the signals from microprocessor FU


2


ports P


2


_


6


and P


2


_


7


will change the tone of the buzzer. Port P


2


_


7


has a dual use for switching on power to the receiver to receive signals from the door lock unit. Power is switched on to the receiver by driving P


2


_


7


high, turning on transistor FQ


2


A, which in turn switches on transistor FQ


2


B, which places signal VREC at approximately the voltage of VBAT, the positive voltage from the battery.




Port P


3


_


1


is an input for receiving data RX from the receiver. Data RX is deciphered by microprocessor FU


2


to determine any message or signal sent from the door unit. The message may be, for example, to generate an audible alarm through the buzzer.




To conserve as much battery power as possible, power to the fob circuitry is enabled only when required. When any of the four switches FSW


1


-


4


is activated, signal VENABLE is driven high to turn on transistor FQ


1


A, which turns on transistor FQ


1


B, applying power through VSWITCH to microprocessor FU


2


. Upon power up, microprocessor FU


2


outputs a logic high on port P


2


_


5


, which is tied to the signal VENABLE. This maintains power after the switch is released. When microprocessor FU


2


has completed the command requested by the user it can power itself down by placing VENABLE in a high impedance state.





FIG. 15

shows the transmitter for the fob. Transmitter


830


generates a pulse-width modulated radio frequency signal based on signal FTXD. A saw resonator FX


1


sets the frequency and a loop of approximately 47 nanohenries, implemented as a circuit trace on the board, provides the antenna for the transmitter. The signal FTXD, generated from microprocessor FU


2


in combination with hopping encoder FU


1


, is the input signal that is modulated by transmitter


830


.




Receiver


836


, shown in

FIG. 16

, receives signals from the door unit, such as a verification that a locking operation has occurred successfully. Receiver


836


has a preamplifier


838


, a super-regenerative, self-quenching oscillator


840


, gain and filtering stage


842


, and a data slicer or data comparator


844


. Receiver


836


is selectively powered by signal VREC, which is generated from transistor FQ


2


B when transistor FQ


2


A is turned on by microprocessor FU


2


driving port P


2


_


7


(FIG.


14


).





FIGS. 17-18

are schematics for the door unit control circuitry that controls and senses the status of the lock and deciphers and generates the transmitted and received signals. The door unit control circuitry is also battery operated. The positive battery terminals are PD


3


and PD


4


. The ground battery terminals are PD


1


and PD


2


. The major circuit blocks included with the control circuitry are motor control circuit


850


, low battery sensing circuit


852


, motor current sensing circuit


854


, sensing switches, DSW


1


, DSW


3


, DSW


4


, common sense circuit


856


, EEPROM DU


6


, and microprocessor DU


8


. Low battery sensing circuit


852


and motor current sensing circuit


854


share common sense circuit


856


, including comparator DU


1


B. Microprocessor DU


8


uses its ports to control or sense the status of the other circuit blocks.




Microprocessor DU


8


has clock inputs OSC


1


/CLKIN and OSC


2


/CLKOUT connected to a crystal DX


2


to provide the clock for normal operation. Microprocessor DU


8


also has clock inputs RC


0


/T


1


OSO/T


1


CK


1


and RC


1


T


1


OSI, which are attached to a 32 kilohertz crystal DX


3


, that provides the low power clock for a sleep mode for microprocessor DU


8


. The power clear input MCLR/VPP is connected to a voltage detector DU


7


that resets microprocessor DU


8


if there is a drop in voltage. The door unit control circuit includes an EEPROM DU


6


for storing the fob serial numbers used to determine whether a signal being received is from an authorized or valid fob. Microprocessor DU


8


ports RA


0


, RA


1


, RA


2


provide a serial interface to EEPROM DU


6


. RA


0


is driven by microprocessor DU


8


to provide the chip select signal CS and RA


1


is similarly driven by microprocessor DU


8


to provide the clock input CLK to EEPROM DU


6


. The data in DI and data out DO pins of the EEPROM are controlled by port RA


2


of microprocessor DU


8


.




Microprocessor DU


8


preferably is a PIC16LCR62/04I/SO processor available from Microchip. Most preferably microprocessor DU


8


has program memory on chip in the form of a ROM. The program memory is used to implement the algorithm for operating and controlling the door unit control circuitry.




Ports RB


1


, RB


2


and RA


4


/TOCKI are the primary inputs and outputs for controlling the operation of the motor. Port RA


4


/TOCKI is connected to switch DSW


5


which is used to select whether the lock is connected to a left or a right-hand door. This is used to determine the direction that the motor must turn to lock or unlock. Port RB


1


is the MOTOR+ output and port RB


2


is the MOTOR− output to motor control circuit


850


. The terminals to the motor are connected at connector P


2


of motor control circuit


850


. The MOTOR+ and MOTOR− outputs drive power FETS DU


2


A, DU


2


B, DU


3


A, DU


3


B, which control the direction of rotation for the motor. If microprocessor DU


8


places the MOTOR+ and MOTOR− outputs in the high and low states, respectively, the motor is turned on in the + direction. If the MOTOR+ and MOTOR− outputs are both placed in the low state or both placed in the high state, then the motor is off. If the MOTOR+ and MOTOR− outputs are placed in the low and high states, respectively, the motor is turned on in the − direction. Whether the + direction or − direction of the motor locks or unlocks is determined by switch DSW


5


.




Switches DSW


1


, DSW


3


and DSW


4


are used to sense the status of the lock. DSW


1


is a normally closed, single-pole, double-throw switch used to detect whether the actuator is in a neutral position. Switches DSW


3


and DSW


4


are normally open, single-pole, double-throw switches that are switched to determine the lock and unlock state, respectively. The switches may be used to sense, for example, the actuating arm or a lever used to rotate the drive bar of the lock.




Switch DSW


2


is a single-pole, single-throw switch or contact used to force the microprocessor DU


8


into a mode to learn fob or erase fob serial numbers in conjunction with the EEPROM DU


6


.




An LED DD


4


is driven from microprocessor port RB


3


and may be used to indicate the status of the door unit, including status about the lock or battery.




Common sense circuit


856


, low battery sensing circuit


852


, and motor current sensing circuit


854


sense low battery conditions and also current conditions in the motor circuit. Low battery sensing circuit


852


has two inputs, LOWBAT


1


and LOWBAT


2


, connected to microprocessor DU


8


ports RC


3


/SCK/SCL and RC


4


/SDI/SDA, respectively. Common sense circuit


856


is used to detect current status as well as low battery status. Comparator DU


1


B has its output CURRENT connected to microprocessor DU


8


input port RA


5


/SS. To save power consumption, the sensing circuitry is only enabled by microprocessor DU


8


under control of a program when it is desired to sense certain conditions. The sensor output SENSOR_ON from the microprocessor port RB


0


/INT is turned on by microprocessor DU


8


whenever a sensing operation is desired. The result of the sensing operation is returned to the microprocessor DU


8


by the CURRENT output from comparator DU


1


B. The power to comparator DU


1


B is controlled by microprocessor DU


8


port RC


2


/CCP


1


(the connection is not shown). When the motor is turned on, current sensing circuit


854


detects the current through the motor by converting the current to a voltage. When the motor is turned off, low battery conditions may be detected sequentially by activating the LOWBAT


1


and LOWBAT


2


signals in conjunction with SENSOR_ON. The resistor values for R


41


and R


42


are used to determine the voltage thresholds that will activate the CURRENT signal when LOWBAT


1


and LOWBAT


2


are activated to turn on transistors DQ


8


and DQ


9


, respectively.




The transmitter


860


and receiver


862


on the door lock unit are shown in

FIGS. 19 and 20

, respectively. The power to the receiver is controlled by a microprocessor DU


8


port RC


5


/SDO, which drives signal RXPOWER. The transmit signal TXD is generated from microprocessor DU


8


port RC


7


and the received signal RXD is received at microprocessor port RC


6


.




The receiver


862


and transmitter


860


are similar to the receiver


836


and transmitter


830


of the fob unit, described above with respect to

FIGS. 15-16

. The receiver has a preamplifier


864


, a super-regenerative, self-quenching oscillator


866


, gain and filtering stage


868


, and a data slicer or data comparator


870


. Power to the receiver is controlled by input RXPOWER from microprocessor DU


8


, which is used to turn on transistor DQ


1


. Similarly, the power to comparator DU


1


A, which converts the received signal to digital logic levels, is controlled by the COMP_ON signal which turns on transistor DQ


2


.




The transmitter


860


, transmits a pulse-width modulated signal. The frequency is set by saw resonator DX


1


and a loop of approximately 47 nanohenries, implemented as a trace on the circuit board, is used as an antenna.




The operation of the electronics for the fob and door unit, shown schematically in

FIGS. 14-20

, may be better understood through the description of one example cycle of operation, such as a lock or unlock request operation. Those skilled in the art will readily recognize that the microprocessor based architectures of the fob and door unit allow considerable flexibility in the control and sensing of status of the actuator.




A user may make a request for a lock or unlock operation by depressing one of the contact switches FSW


1


, FSW


2


, FSW


3


, FSW


4


. This causes the VENABLE signal to become active, which in turn activates transistor FQ


1


A and transistor FQ


1


B to power signal VSWITCH. Signal VSWITCH powers microprocessor FU


2


and hopping encoder FU


1


. After receiving power, microprocessor FU


2


asserts the VENABLE signal to maintain power.




Microprocessor FU


2


, under software control, decodes the user's request based on the switch depressed. Based on the request, for example lock or unlock, decoded by microprocessor FU


2


, an appropriate signal is generated to be transmitted. The signal may be encoded by using hopping encoder FU


1


or may be sent unencoded using port P


2


_


4


to generate signal FTXD, which is then converted into a pulse-width modulated RF signal by transmitter


830


. Preferably, an unencoded preamble signal is sent first, then followed by an encoded signal.




The signal transmitted by transmitter


830


is received by receiver


862


of the door unit. The received signal is amplified by preamplifier


864


, then sensed by super-regenerative self-quenching oscillator


866


. The remaining signal is amplified by gain and filtering stage


868


and finally converted into digital logical levels by data slicer


870


. Receiver


862


and comparator DU


1


A are powered by activation of RXPOWER and COMP_ON from microprocessor DU


8


of the door unit. RXPOWER and COMP_ON are activated periodically every 200 milliseconds for 2-5 milliseconds to detect a preamble. If a preamble is detected then microprocessor DU


8


maintains power until the signal from transmitter


830


is completely received.




Data slicer


870


outputs the received signal RXD to microprocessor DU


8


. Microprocessor DU


8


deciphers the signal RXD to determine whether the signal was received from a valid fob. This is accomplished by the microprocessor DU


8


first powering signal SENSOR_ON to compare the serial number transmitted in signal RXD with the valid serial numbers stored in EEPROM DU


6


. If the signal transmitted by the fob is appropriate, then microprocessor DU


8


continues processing. Otherwise, microprocessor DU


8


ignores the received signal.




Microprocessor DU


8


deciphers signal RXD to determine the operation requested by the fob. However, prior to acting upon the request, microprocessor DU


8


may sequentially enable the LOWBAT


1


and LOWBAT


2


signals to insure that the batteries have sufficient power for completing the requested operation and otherwise detect low battery conditions. If the batteries have sufficient power, the motor of the actuator may be enabled by microprocessor DU


8


by activating the MOTOR+ and MOTOR− inputs in accordance with switch DSW


5


. While the motor is in operation, the current in the motor may be sensed by motor sensing circuit


854


and common sense circuit


856


.




Microprocessor DU


8


may monitor the completion of the requested operation through switches DSW


1


, DSW


3


and DSW


4


. Upon completion of the request, LED DD


4


may be set in accordance with a predetermined scheme, for example, LED DD


4


may flash twice to indicate successful completion. The status of the actuator may then be transmitted via signal TXD and transmitter


860


.




After transmitting a signal, fob unit microprocessor FU


2


enables its receiver in anticipation of receiving status from the door unit. The receiver is enabled by activating transistor FQ


2


A, which activates transistor FQ


2


B to supply signal VREC to power the receiver. Microprocessor FU


2


may enable receiver


836


for a predetermined amount of time after transmitting a request and then disable receiver


836


after receiving a response or after the predetermined amount of time, if no response is received. Receiver


836


receives the signal and supplies it to microprocessor FU


2


via signal RX. Signal RX is deciphered by microprocessor FU


2


, which in turn may generate, for example, an audible alarm via a buzzer.




A mechanical arrangement for switches DSW


1


, DSW


3


and DSW


4


with respect to actuator


800


is shown in

FIG. 21

, which is a side view. A portion of actuating arm


808


rests on a guide


874


. Switches DSW


1


, DSW


3


and DSW


4


are mounted on a printed circuit board


876


, which preferably has the door unit circuitry mounted thereon and is mounted above guide


874


. Switch DSW


1


is positioned such that contact is made between a portion of actuating arm


808


and switch DSW


1


when actuating arm


808


is in the neutral position. DSW


3


is positioned such that contact is made between a portion of actuating arm


808


and switch DSW


3


when actuating arm


808


is in the lock position. Similarly, switch DSW


4


is positioned such that contact is made between a portion of actuating arm


808


and switch DSW


4


when actuating arm


808


is in the unlock position. Contact between actuating arm


808


and switch DSW


4


is shown in FIG.


21


.




The actuator assemblies described above and shown in

FIGS. 1-6

may be readily retrofit on an existing lock or dead-bolt assembly. To facilitate retrofitting an existing lock or dead-bolt assembly, a plate


134


including a mounting portion


702


and a support portion


704


is provided as shown in

FIGS. 9-12

. In

FIG. 9

, mounting portion


702


is shown in a first position wherein a first set of holes, including center hole


708


and perimeter holes


710


are aligned with an opening


712


in support portion


704


. In

FIG. 10

, mounting portion


702


is shown in a second position wherein a second set of holes, including center hole


716


and perimeter holes


718


are aligned with opening


712


.




Center holes


708


,


716


are for receiving the drive bar and perimeter holes


710


,


718


are for receiving the bolts that hold the lock to the door. In the preferred embodiment, the first and second set of holes are sized and spaced to accommodate a number of different locks from a variety of lock manufacturers. For example, mounting portion


702


shown in

FIGS. 9-10

has circular center holes


710


,


718


spaced 1.875 inches apart from center to center having diameters of 1.2 inches. Perimeter holes


710


,


718


are generally oval in shape with holes


710


being rotated approximately ninety degrees from holes


718


.




As shown in

FIGS. 11 and 12

, support portion


704


has a recess portion


720


for receiving mounting portion


702


. Similarly, mounting portion


702


has a recessed portion


722


and flanged end portions


724


. Formed within recessed portion


720


are protrusions


726


. A first pair of notches


728


and a second pair of notches


730


are provided in mounting portion


702


for alternatively mating with protrusions


726


to align mounting portion


702


in the first and second positions shown in

FIGS. 9 and 10

, respectively.




To retrofit an existing lock using plate


134


, first, the interior cylinder or knob is removed. Then, support portion


704


, preferably including a preassembled actuator assembly, such as assembly


12


, assembly


112


, assembly


212


, or assembly


312


is positioned over the exterior cylinder and existing mounting hardware. For example, for assembly


312


shown in

FIGS. 4

,


4


A and


4


B, the preassembled actuator assembly may include motor


320


, threaded rod


322


, actuating arm


324


and any appropriate circuitry, including any sensors desired, prearranged and assembled onto plate


134


. Next mounting portion


702


is positioned over the existing mounting hardware by alignment in either the first or second position. Then, a rotating device, such as adaptor


26


and lever


28


, lever


128


, lever


238


, lever


328


or adaptor


329


, is secured onto the drive bar. Finally, a protective cover may be provided over plate


134


and the interior cylinder or knob may be retrofit onto the extended drive bar, completing the retrofit of an actuator assembly onto an existing lock or dead-bolt assembly.




An alternate and preferred method for retrofitting the actuator assemblies described above, and in particular, actuator


800


shown in

FIG. 13

is described below with respect to

FIGS. 22 and 23

, which show exploded views of actuator


800


and an adaptor


880


.

FIG. 22

shows a knob


882


, a cover


884


, a lever assembly


886


, base plate


812


and adaptor


880


.

FIG. 23

shows adaptor


880


and base plate


812


. Mounted on base plate


812


is actuator


800


and a printed circuit board


876


with the door unit circuitry mounted thereon. Slidably disposed within a recessed portion of base plate


812


is a mounting plate


890


. Cover


884


encases and covers a surface of base plate


812


, actuator


800


, and printed circuit board


876


.




To retrofit an existing lock, a preassembled actuator assembly is provided, including an attached combination of knob


882


, cover


884


, lever assembly


886


, and base plate


812


. Knob


882


could be a cylinder rather than a knob. Adaptor


880


includes an aperture


881


sized and configured to fit a drive bar. Aperture


881


may be varied in size and configuration to fit drive bars from different lock manufacturers. The interior cylinder or knob is removed from the existing dead bolt or lock assembly. Then the appropriate adaptor, i.e., one that fits the drive bar, is placed over the drive bar of the existing lock. The preassembled actuator is aligned over the adaptor such that the drive bar extension


892


fits in a bore


894


of lever assembly


886


. Drive bar extension


892


and bore


894


are both rectangular in configuration so that drive bar extension


892


may snugly fit within bore


894


such that rotation of lever assembly


886


causes rotation of adaptor


880


. Mounting plate


890


is aligned so that screws or bolts may be replaced in holes


896


. Then the preassembled actuator is secured in place. As an alternative, the adaptor may be placed in the preassembled actuator prior to placing the adaptor and preassembled actuator over the drive bar of the existing lock. This method of retrofitting to an existing lock advantageously allows the actuator to remain concealed within its housing during installation.




Described above is an electrically operated actuator that is capable of automating locking and unlocking of door locks and dead-bolt assemblies, while preserving the conventional manual operation of such locks and assemblies. Additionally, the electrically operated actuator is readily retrofit on an existing lock or dead-bolt assembly.




While the present invention has been described with respect to certain preferred embodiments and modifications thereof, it will be appreciated by those skilled in the art that certain other modifications are possible and fall within the scope of the invention as expressed in the accompanying claims.



Claims
  • 1. An electrically operated actuator in combination with a dead bolt assembly, the dead bolt assembly comprising a lock having a drive bar and a bolt, the bolt being operably coupled to the drive bar such that rotation of the drive bar extends and retracts the bolt linearly, the actuator comprising:means for rotating the drive bar to extend and retract the bolt; means for driving said rotating means, said driving means being responsive to an electrical signal; wherein said electrical signal is generated by: a wireless transmitter that transmits a request to actuate the actuator; a wireless receiver that receives the request to actuate the actuator; and a control circuit, operably connected to said wireless receiver, the control circuit providing said electrical signal to said driving means if the request is valid; and wherein said rotating means comprises: a resilient lever attached to the drive bar, said resilient lever being pivotal about an axis that is coaxial to an axis of rotation of the drive bar; and wherein said driving means comprises: a motor capable of rotating a threaded rod that extends from said motor; a threaded member screwed onto said threaded rod; a guide preventing rotation of said threaded member; and said threaded member being adapted to frictionally engage and to rotate said resilient lever.
  • 2. The actuator of claim 1 wherein said threaded member includes a protrusion and said guide forms a channel wherein said protrusion is slidably retained.
  • 3. The actuator of claim 1 wherein said threaded rod is oriented to be perpendicular to the bolt.
  • 4. The actuator of claim 1 wherein said threaded rod is oriented to be parallel to the bolt.
  • 5. An electrically operated actuator in combination with a dead bolt assembly, the dead bolt assembly comprising a lock having a drive bar and a bolt, the bolt being operably coupled to the drive bar such that rotation of the drive bar extends and retracts the bolt linearly, the actuator comprising:means for rotating the drive bar to extend and retract the bolt; means for driving said rotating means, said driving means being responsive to an electrical signal; wherein said electrical signal is generated by: a wireless transmitter that transmits a request to actuate the actuator; a wireless receiver that receives the request to actuate the actuator; and a control circuit, operably connected to said wireless receiver, the control circuit providing said electrical signal to said driving means if the request is valid; and wherein said rotating means comprises: a lever attached to the drive bar, said lever being pivotal about an axis that is coaxial to an axis of rotation of the drive bar; and said driving means comprises: a motor capable of bidirectional rotation of a rod extending from said motor; said rod having a first gear with a threaded exterior surface; a second gear having teeth, said second gear being oriented to engage the threaded exterior surface of the first gear such that rotation of the first gear causes rotation of the second gear; and said second gear having a plurality of protrusions positioned on a surface of said second gear to contact and to rotate said lever.
  • 6. The actuator of claim 5 wherein said second gear is circular.
  • 7. The actuator of claim 5 wherein said rod is oriented perpendicular to the bolt.
  • 8. The actuator of claim 5 wherein said second gear has three protrusions positioned on its surface.
  • 9. The actuator of claim 5 wherein said lever is resilient in a direction parallel to the axis of rotation of said drive bar.
  • 10. The actuator of claim 5 wherein said second gear has two protrusions positioned on its surface.
  • 11. The actuator of claim 5 wherein said rod is oriented parallel to the bolt.
  • 12. An electrically operated actuator in combination with a dead bolt assembly, the dead bolt assembly comprising a lock having a drive bar and a bolt, the bolt being operably coupled to the drive bar such that rotation of the drive bar extends and retracts the bolt linearly, the actuator comprising:means for rotating the drive bar to extend and retract the bolt; means for driving said rotating means, said driving means being responsive to an electrical signal; wherein said electrical signal is generated by: a wireless transmitter that transmits a request to actuate the actuator; a wireless receiver that receives the request to actuate the actuator; and a control circuit, operably connected to said wireless receiver, the control circuit providing said electrical signal to said driving means if the request is valid; and wherein said rotating means comprises: a lever attached to the drive bar, said lever being pivotal about an axis that is coaxial to an axis of rotation of the drive bar; and said driving means comprises: a first solenoid having a first core that extends and retracts in response to a first solenoid signal, said first core being positioned to pivot said lever from a first position wherein said bolt is completely retracted and a second position, wherein said bolt is completely extended; and a second solenoid having a second core that extends and retracts in response to a second solenoid signal, said second core being positioned to pivot said lever from said second position to said first position.
  • 13. The actuator of claim 12 wherein said first and second solenoids are oriented such that the cores of said first and second solenoids are perpendicular to the bolt.
  • 14. The actuator of claim 12 wherein said first and second solenoids are oriented such that the cores of said first and second solenoids are parallel to the bolt.
  • 15. The actuator of claim 1 wherein the control circuit comprises a plurality of sensing circuits for sensing a status of the dead bolt assembly.
  • 16. The actuator of claim 15 wherein the status includes at least one of a low battery indication, a motor current, and a lock position.
  • 17. The actuator of claim 16 wherein the transmitter is a first transceiver and the receiver is a second transceiver and the status is transmitted to the first transceiver by the second transceiver.
  • 18. The actuator of claim 17 wherein the status is reflected at the first transceiver by an audible or visual indication.
  • 19. A method for controlling power to a receiver that receives a signal indicating a status of a lock controlled by an electrically operated actuator, the method comprising the steps of:(a) switching on power to the receiver after transmitting a lock or unlock signal; and (b) switching power off to the receiver upon the first to occur of a predetermined period of time or a receipt of the signal indicating the status of the lock; and wherein the status includes at least one of lock status, unlock status, rotor current sense, and low battery condition.
  • 20. The method of claim 19 further comprising the step of making a visually perceptible indication of the status.
  • 21. The method of claim 19 further comprising the step of making an audible indication of the status.
  • 22. A method for controlling power to a receiver that receives a signal that is used to extend or retract a bolt in a lock controlled by an electrically operated actuator, the method comprising the steps of:(a) periodically switching power on to the receiver; (b) switching power to the receiver off after a valid signal is received indicating that the bolt should be extended or retracted; and (c) switching power to the receiver off after a predetermined period of time, if a valid signal is not received during the predetermined amount of time.
  • 23. The method of claim 22 wherein said step of periodically switching power on to the receiver includes switching power on to the receiver approximately every 200 milliseconds.
  • 24. The method of claim 22 wherein said predetermined amount of time is about 2 to 5 milliseconds.
  • 25. The method of claim 22 wherein step (a) further includes maintaining power to the receiver if a valid preamble signal is received by the receiver, the valid preamble signal being an indication that a transmitter is transmitting.
  • 26. The method of claim 25 wherein power is maintained until the transmitter completes a transmission.
  • 27. An electrically operated actuator in combination with a dead bolt assembly, the dead bolt assembly comprising a lock having a drive bar and a bolt, the bolt being operably coupled to the drive bar such that rotation of the drive bar extends and retracts the bolt linearly, the actuator comprising:a drive bar attachment for rotating the drive bar to extend and retract the bolt; a motor operably coupled to the drive bar attachment to rotate the drive bar attachment, the motor being responsive to an electrical signal; wherein said electrical signal is generated by: a wireless transmitter that transmits a request to actuate the actuator; a wireless receiver that receives the request to actuate the actuator; a control circuit, operably connected to said wireless receiver, the control circuit providing said electrical signal to said motor if the request is valid; and wherein the control circuit comprises at least one sensing circuit for sensing a status of the dead bolt assembly.
  • 28. The actuator of claim 27 wherein the status includes at least one of a low battery indication and a lock position.
  • 29. An electrically operated actuator in combination with a dead bolt assembly, the dead bolt assembly comprising a lock having a drive bar and a bolt, the bolt being operably coupled to the drive bar such that rotation of the drive bar extends and retracts the bolt linearly, the actuator comprising:a drive bar attachment for rotating the drive bar to extend and retract the bolt; a motor operably coupled to the drive bar attachment to rotate the drive bar attachment, the motor being responsive to an electrical signal; wherein said electrical signal is generated by: a wireless transmitter that transmits a request to actuate the actuator; a wireless receiver that receives the request to actuate the actuator; a control circuit, operably connected to said wireless receiver, the control circuit providing said electrical signal to said motor if the request is valid; and wherein the wireless transmitter is a first transceiver and the wireless receiver is a second transceiver and a status of the dead bolt assembly is transmitted to the first transceiver by the second transceiver.
  • 30. The actuator of claim 29 wherein the status is reflected at the first transceiver by an audible or visual indication.
  • 31. An electrically operated actuator in combination with a dead bolt assembly, the dead bolt assembly comprising a lock having a drive bar and a bolt, the bolt being operably coupled to the drive bar such that rotation of the drive bar extends and retracts the bolt linearly, the actuator comprising:means for rotating the drive bar to extend and retract the bolt; means for driving said rotating means, said driving means being responsive to an electrical signal; means for disengaging said rotating means from said driving means for manual rotation of the drive bar; wherein said electrical signal is generated by: a wireless transmitter that transmits a request to actuate the actuator; a wireless receiver that receives the request to actuate the actuator; and a control circuit, operably connected to said wireless receiver, the control circuit providing said electrical signal to said driving means if the request is valid.
  • 32. The actuator of claim 31 wherein the rotating means comprises a drive bar attachment.
  • 33. The actuator of claim 31 wherein the driving means comprises a motor.
  • 34. The actuator of claim 32 wherein the means for disengaging comprises a selective contact between the drive bar attachment and the driving means.
  • 35. An electrically operated actuator in combination with a dead bolt assembly, the dead bolt assembly comprising a lock having a drive bar and a bolt, the bolt being operably coupled to the drive bar such that rotation of the drive bar extends and retracts the bolt linearly, the actuator comprising:a drive bar attachment that is coupled to the drive bar to extend and retract the bolt linearly; a motor being responsive to an electrical signal; a gear assembly operably coupled to the motor to respond to rotation of said motor, the gear assembly being coupled to said drive bar attachment to engage said drive bar attachment to extend or retract the bolt linearly, and the gear assembly being coupled to said drive bar attachment to disengage from said drive bar attachment for manual rotation of the drive bar; wherein said electrical signal is generated by a circuit comprising: a wireless transmitter that transmits a request to actuate the actuator; a wireless receiver that receives the request to actuate the actuator; a control circuit operably connected to said receiver, the control circuit providing said electrical signal to said motor if the request is valid.
  • 36. The actuator of claim 35 wherein the gear assembly includes a gear with at least one protrusion and said at least one protrusion is adapted to engage said drive bar attachment to extend and retract the bolt linearly.
  • 37. The actuator of claim 36 wherein said at least one protrusion is adapted to frictionally engage said drive bar attachment to extend and retract the bolt linearly.
  • 38. The actuator of claim 36 wherein the gear has teeth on an arcuate perimeter and the at least one protrusion extends outwardly from a surface of the gear, the surface being orthogonal to the arcuate perimeter of the gear.
  • 39. The actuator of claim 35 wherein said drive bar attachment is a lever that is coupled to the drive bar.
  • 40. The actuator of claim 36 wherein the at least one protrusion is also adapted to disengage with said drive bar attachment in response to rotation of said drive bar attachment for fail safe operation.
  • 41. The actuator of claim 40 wherein the at least one protrusion is also adapted to flexibly disengage with said drive bar attachment.
  • 42. The actuator of claim 36 wherein the at least one protrusion is adapted to disengage with said drive bar attachment in response to rotation of the gear assembly to place the drive bar attachment in a state whereby the bolt may be extended or retracted manually.
  • 43. The actuator of claim 35 wherein the control circuit comprises at least one sensing circuit for sensing a status of the dead bolt assembly and wherein the status includes at least one of a low battery indication, a motor current, and a lock position.
  • 44. The actuator of claim 35 wherein the wireless transmitter is a first transceiver and the wireless receiver is a second transceiver and a status of the dead bolt assembly is transmitted to the first transceiver by the second transceiver.
  • 45. The actuator of claim 38 wherein the status is reflected at the first transceiver by an audible or visual indication.
CROSS REFERENCES TO RELATED APPLICATIONS

This is a continuation application of U.S. patent application Ser. No. 09/368,376 filed Aug. 4, 1999, now U.S. Pat. No. 6,089,058, which is a continuation application of U.S. patent application Ser. No. 08/950,875 filed Oct. 15, 1997, now U.S. Pat. No. 5,979,199, which is a continuation-in-part of patent application Ser. No. 08/713,895 filed Sep. 13, 1996, now U.S. Pat. No. 5,896,769.

US Referenced Citations (71)
Number Name Date Kind
559308 Palmer Apr 1896
2665577 Sanowskis Jan 1954
2750786 Sanowskis Jun 1956
3733861 Lester May 1973
3767240 Belanger Oct 1973
4135377 Kleefeldt et al. Jan 1979
4148092 Martin Apr 1979
4317147 Daughenbaugh et al. Feb 1982
4317157 Eckloff Feb 1982
4438962 Soloviff et al. Mar 1984
4568998 Kristy Feb 1986
4596985 Bongard et al. Jun 1986
4631527 De Witt et al. Dec 1986
4665727 Uyeda May 1987
4677834 Hicks Jul 1987
4691542 Young Sep 1987
4743898 Imedio May 1988
4786900 Karasawa et al. Nov 1988
4802353 Corder et al. Feb 1989
4805781 Tegel Feb 1989
4808995 Clark et al. Feb 1989
4848115 Clarkson et al. Jul 1989
4849749 Fukamachi et al. Jul 1989
4854143 Corder et al. Aug 1989
4864494 Kobus, Jr. Sep 1989
4893704 Fry et al. Jan 1990
4931789 Pinnow Jun 1990
4956984 Chi-Cheng Sep 1990
4967305 Murrer et al. Oct 1990
4995248 Liu Feb 1991
5010752 Lin Apr 1991
5103221 Memmola Apr 1992
5107258 Soum Apr 1992
5124565 Yoshida et al. Jun 1992
5148691 Wallden Sep 1992
5199288 Merilainen et al. Apr 1993
5204672 Brooks Apr 1993
5251466 Chang Oct 1993
5280881 Karmin Jan 1994
5328218 Brusasco et al. Jul 1994
5379033 Fujii et al. Jan 1995
5392025 Figh et al. Feb 1995
5406274 Lambropoulos et al. Apr 1995
5441315 Kleefeldt et al. Aug 1995
5442341 Lambropoulos Aug 1995
5475377 Lee Dec 1995
5486812 Todd Jan 1996
5487289 Otto, III et al. Jan 1996
5504478 Knapp Apr 1996
5508687 Gebhardt et al. Apr 1996
5526710 Ohta Jun 1996
5531086 Bryant Jul 1996
5544507 Lin Aug 1996
5610587 Fujiuchi et al. Mar 1997
5628535 Buscher et al. May 1997
5634676 Feder Jun 1997
5678436 Alexander Oct 1997
5712626 Andreou et al. Jan 1998
5729198 Gorman Mar 1998
5790034 Khoury Aug 1998
5852944 Collard, Jr. et al. Dec 1998
5857365 Armstrong Jan 1999
5878530 Eccleston et al. Mar 1999
5896769 Elpern et al. Apr 1999
5933086 Tischendorf et al. Aug 1999
5979199 Elpern et al. Nov 1999
6032500 Collard, Jr. et al. Mar 2000
6035676 Hudspeth Mar 2000
6089058 Elpern et al. Jul 2000
6107934 Andreou et al. Aug 2000
6116067 Myers et al. Sep 2000
Non-Patent Literature Citations (3)
Entry
Weiser Lock Powerbolt Electronic Keyless Entry System Packaging, © 1996.
Weiser Lock Powerbolt, Installation & Programming Instructions Owner's Manual, No Date.
Photographs of the Weiser Lock Powerbolt.
Continuations (2)
Number Date Country
Parent 09/368376 Aug 1999 US
Child 09/564938 US
Parent 08/950875 Oct 1997 US
Child 09/368376 US
Continuation in Parts (1)
Number Date Country
Parent 08/713895 Sep 1996 US
Child 08/950875 US